Komatsu Excavator PC500LC-8R service & repair manual

Description Komatsu Excavator PC500LC-8R service & repair manual

Komatsu Hydraulic Excavator PC500LC-8R pdf workshop service repair manual

Serial numbers:
75979 and up

Technical data, specifications, testing, troubleshooting, maintenance, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

Specification
Specification and technical data
Specification dimension drawings
Weight table
Table of fuel, coolant and lubricants

Structure, function and maintenance standard
Engine and cooling system
Engine related parts
Radiator, oil cooler and aftercooler
Power train
Swing circle
Swing machinery
Final drive
Sprocket
Undercarriage and frame
Track frame and idler cushion
Track shoe
Triple-grouser shoe
Idler
Carrier roller
Track roller
Hydraulic system
Hydraulic equipment layout drawing
Hydraulic tank and filter
Hydraulic pump
Control valve
CLSS
Functions and operation by valve
Merge-divider valve
Attachment circuit selector valve
Holding valve
Valve control
PPC valve
Solenoid valve
PPC accumulator
Return oil filter
Center swivel joint
Travel motor
Swing motor
Hydraulic cylinder
Work equipment
Dimensions of components
Cab and its attachments
Air conditioner piping
Electrical system
Engine control
Electronic control system
Monitor system
Sensors
KOMTRAX system

Standard value table
Standard service value table
Standard value table for engine related parts
Standard value table for chassis related parts

Testing and adjusting
Related information on testing and adjusting
Tools for testing, adjusting and troubleshooting
Sketches of special tools
Engine and cooling system
Measuring engine speed
Measuring air boost pressure
Measuring exhaust gas temperature
Measuring exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Testing engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Measuring fuel pressure
Handling during cylinder cut-out operation
Handling during no injection cranking operation
Measuring fuel return rate and leakage
Bleeding air from fuel circuit
Checking fuel circuit for leakage
Checking and adjusting fan belt and alternator belt
Checking and adjusting air conditioner compressor belt tension
Power train
Testing swing circle bearing clearance
Undercarriage and frame
Testing and adjusting track shoe tension
Hydraulic system
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits
Measuring control circuit basic pressure
Checking and adjusting pump PC control circuit oil pressure
Checking and adjusting pump LS control circuit oil pressure
Measuring solenoid valve output pressure
Measuring PPC valve output pressure
Adjusting play of work equipment and swing PPC valves
Inspecting locations of hydraulic drift of work equipment
Releasing residual pressure from hydraulic circuit
Measuring oil leakage amount
Bleeding air from various parts
Electrical system
Special functions of machine monitor
Handling voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Procedure for testing diodes
Pm Clinic
Pm Clinic service
Undercarriage troubleshooting report

Troubleshooting
General Information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and troubleshooting steps
Information in troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Failure code table and fuse locations
Failure codes table
Fuse locations
Troubleshooting by failure code (Display of code)
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
Related information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of engine and hydraulic oil pump assembly
Power train
Removal and installation of travel motor and final drive assembly
Disassembly and assembly of final drive
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing motor and swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Separation and connection of track shoe assembly
Removal and installation of sprocket
Removal and installation of idler and idler cushion assembly
Disassembly and assembly of idler
Disassembly and assembly of idler cushion
Disassembly and assembly of track roller
Disassembly and assembly of carrier roller
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Removal and installation of hydraulic pump assembly
Removal and installation of oil seal in hydraulic pump input shaft
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of work equipment assembly
Cab and its attachments
Removal and installation of operator cab assembly
Removal and installation of operator cab glass (stuck glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Removal and installation of work equipment control lever assembly
Electrical system
Removal and installation of air conditioner unit assembly
Removal and installation of KOMTRAX communication modem assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly
Removal and installation of engine controller

Diagrams and drawings
Hydraulic diagrams and drawings
Hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram
Connector arrangement diagram

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